Method for manufacturing a stator and method for manufacturing a rotating electric machine

Abstract

To solve the problem in which, in a structure where only an insulator of a stator core is connected, the gripping force is weak and the stator core may be split in a process of manufacturing a motor by combining a stator and a rotor.SOLUTION: It is possible to provide a manufacturing method of a stator having stable magnetic properties, which prevents splitting and misalignment of a stator core by melting and fixing at least a part or the whole of either of a joint portion of adjacent split cores and a joint portion of adjacent insulators of the stator core arranged in a circular shape.SELECTED DRAWING: Figure 13

Description

Technical Field

[0001] This application relates to a method for manufacturing a stator and a method for manufacturing a rotating electric machine.

Background Art

[0002] There is known a structure in which an end portion of one adjacent insulator attached to a stator core has a connecting means for an arcuate convex portion, an end portion of the other insulator has a connecting means for a concave portion, and the connecting body of the stator core is deformed from a linear shape to an annular shape by a hinge structure formed by the connecting means of the convex portion and the concave portion to assemble the stator (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in such a stator, since it is a structure that only connects the insulators, the gripping force is weak, and there is a risk that the stator core may be divided in the process of manufacturing a motor by combining the stator and the rotor. In addition, there is also a problem that the stator core is not uniformly assembled on the ring, resulting in a decrease in the efficiency of the motor.

[0005] This application has been made to solve the above problems, and an object thereof is to provide a method for manufacturing a stator that prevents division and displacement of the stator core and has stable magnetic characteristics.

Means for Solving the Problems

[0006] A method for manufacturing a stator disclosed herein is a method in which a plurality of stator cores, each having a segmented core and an insulator that insulates the segmented core from the windings, are arranged in a ring shape and assembled. The stator core is arranged in a ring shape, and after engaging a projection formed at the end of one insulator with a slit formed at the end of the other insulator, the projection is melted and the molten projection flows into the slit. Its characteristic feature is that it is fixed in place. [Effects of the Invention]

[0007] The method for manufacturing a stator disclosed herein provides a method for manufacturing a stator with stable magnetic properties by melting and fixing at least part or all of the engaging portions of adjacent segmented cores of an annularly arranged stator core and the engaging portions of adjacent insulators, thereby preventing the stator core from splitting and shifting. [Brief explanation of the drawing]

[0008] [Figure 1] This is a perspective view of the stator and rotor constituting the rotating electric machine according to Embodiment 1. [Figure 2] This is a perspective view of the stator according to Embodiment 1. [Figure 3] This is a top view of the stator according to Embodiment 1. [Figure 4] This is a perspective view of the stator core according to Embodiment 1. [Figure 5] This is a front view of the stator core according to Embodiment 1. [Figure 6] This diagram illustrates how to connect the stator core according to Embodiment 1. [Figure 7] This is a side view of the stator during an intermediate assembly process according to Embodiment 1. [Figure 8] This is a partially enlarged view of the upper surface of the stator during an intermediate assembly process according to Embodiment 1. [Figure 9] This is an enlarged view of the area shown in section A of Figure 7. [Figure 10] This is a diagram illustrating the state of the molten protrusion according to Embodiment 1. [Figure 11]It is a diagram for explaining the positioning of the stator core according to Embodiment 2. [Figure 12] It is a perspective view showing a state where the upper insulator according to Embodiment 2 is in contact. [Figure 13] It is a diagram for explaining the heating part of the upper insulator according to Embodiment 2. [Figure 14] It is a perspective view of a stator in an intermediate assembly process according to Embodiment 3. [Figure 15] It is a perspective view of a stator in an intermediate assembly process according to Embodiment 4. [Figure 16] It is a diagram for explaining the connection of the split core according to Embodiment 5.

Modes for Carrying Out the Invention

[0009] Hereinafter, preferred embodiments of the method for manufacturing a stator according to the present application will be described with reference to the drawings. Note that the same reference numerals are assigned to the same contents and corresponding parts, and detailed descriptions thereof are omitted. The same applies to the following embodiments, and duplicate descriptions of configurations with the same reference numerals are omitted.

[0010] Embodiment 1. The stator of the rotating electrical machine in Embodiment 1 will be described with reference to FIG. 1. FIG. 1 is a perspective view of a stator 1 and a rotor 2 constituting a rotating electrical machine. The rotor 2 is arranged to face the stator 1 through a gap on the inner peripheral surface of the stator 1, and a rotating shaft 3 fixed to the rotor 2 is rotatably supported by a bearing (not shown). Therefore, when manufacturing a rotating electrical machine, it is necessary to add a step of attaching the rotor 2 to the manufactured stator 1. The structure and manufacturing method of the rotating electrical machine are the same in Embodiments 2 to 5.

[0011] As shown in FIGS. 2 and 3, the stator 1 is configured by annularly combining a split core 4, which is a magnetic pole, and a stator core 5 having an insulator that insulates between the split core 4 and the winding. The insulator consists of an upper insulator 6 and a lower insulator 7. In the following description, the circumferential direction refers to the circumferential direction of the stator 1, the axial direction refers to the length direction of the rotation axis 3, and the radial direction refers to the radial direction of the stator 1.

[0012] A copper wire or an aluminum wire is wound around the outer periphery of the stator core 5 through the upper insulator 6 and the lower insulator 7 to form a coil. In this embodiment, for ease of explanation, the coil is omitted from the figure. The same applies to other embodiments.

[0013] Next, a method for manufacturing the stator 1 by combining the stator cores 5 will be described. FIG. 4 is a perspective view of the stator core 5. The stator core 5 has a split core 4 in the center, an upper insulator 6 above the split core 4 in the axial direction, and a lower insulator 7 below the split core 4 in the axial direction. The split core 4, the upper insulator 6, and the lower insulator 7 are each configured to be arranged horizontally with respect to the axial direction. The split core 4 is formed by joining a number of thin electromagnetic steel sheets axially by caulking, welding, or adhesion, etc., to form a back yoke portion 8, a tooth portion 9, and a tooth tip portion 10.

[0014] The back yoke portion 8 is formed to be annular around the rotation axis when the stator 1 is assembled, and the tooth portion 9 protrudes from the back yoke portion 8 toward the inner diameter side. The tooth tip portion 10 is provided on the inner diameter side of the tooth portion 9 and protrudes in the circumferential direction from the tooth portion 9, similar to the back yoke portion 8.

[0015] Figure 5 is a front view of the stator core 5 as seen from the radially inner side. As shown in Figure 5, the upper insulator 6 has an upper insulator projection 11 at one end in the circumferential direction and an upper insulator hole 12 at the other end, and the lower insulator 7 has a lower insulator hole 13 at one end in the circumferential direction and a lower insulator projection 14 at the other end. The upper insulator projection 11 and the upper insulator hole 12 are located at the circumferential ends of the divided core 4, and similarly the lower insulator hole 13 and the lower insulator projection 14 are located at the circumferential ends of the divided core 4. In addition, the upper insulator projection 11 and the lower insulator projection 14 are formed to protrude from the upper insulator hole 12 and the lower insulator hole 13. As described later, it is desirable that the length of the protruding portion is such that when it is melted by heating, it produces a sufficient amount of melt to fix the engagement portion between the upper insulator projection 11 and the upper insulator hole 12, and the engagement portion between the lower insulator projection 14 and the lower insulator hole 13.

[0016] The upper insulator projection 11, the lower insulator projection 14, the upper insulator hole 12, and the lower insulator hole 13 are always in the same position in the circumferential direction of the divided core 4. However, the center positions of the upper insulator projection 11 and the lower insulator projection 14 and the upper insulator hole 12 and the lower insulator hole 13 do not need to be on the same axis.

[0017] When arranging the stator cores 5 configured in this way in a ring shape, first, the stator cores 5 are positioned using the upper insulator protrusions 11 and lower insulator protrusions 14 of all stator cores 5 as a reference. Then, as shown in Figure 6, the stator cores 5 are arranged in a ring shape by shifting adjacent stator cores 5 using the upper insulator protrusions 11 and lower insulator protrusions 14 as a reference.

[0018] Subsequently, using the upper insulator projection 11 and the lower insulator projection 14 as a reference (center), the stator core 5 is rotated and inserted into the upper insulator hole 12 and the lower insulator hole 13 of the adjacent stator core 5, respectively. This allows the stator core 5, which constitutes the stator 1 of the rotating electric machine, to be simultaneously positioned and fixed along the true circle of the rotating electric machine.

[0019] Figures 7 and 8 show a stator 1 in the process of assembly, with the stator cores 5 arranged in a ring shape and fixed in place. Figure 7 is a side view of the stator 1, and Figure 8 is a partially enlarged view from above. As shown in Figure 8, the upper insulator projection 11 is inserted into the upper insulator hole 12 of an adjacent stator core 5. Although not shown in the illustration, similarly, the lower insulator projection 14 of an adjacent stator core 5 is inserted into the lower insulator hole 13. In this way, adjacent stator cores 5 are connected and combined in a ring shape. As a result, as shown in Figure 8, the divided cores 4 of adjacent stator cores 5 are fixed in contact with each other. For convenience during insertion, slits 15 (see Figures 4 and 7) are provided in the upper insulator hole 12 and the lower insulator hole 13.

[0020] Next, as explained in Figure 9, which is an enlarged view of section A in Figure 7, all stator cores 5 are positioned and assembled in an annular shape. Then, the area around the upper insulator protrusion 11 and the upper insulator hole 12 of each stator core 5 is heated, melted, and integrated. Although not shown, the engagement portion between the lower insulator hole 13 and the lower insulator protrusion 14 is also melted and integrated.

[0021] Specifically, the portion of the upper insulator projection 11 that protrudes from the upper insulator hole 12 is heated and melted, and the heat is then transferred to the engaging portion 16 of the upper insulator projection 11 and the upper insulator hole 12, causing them to melt and become one. At this time, as shown in Figure 10, the molten insulator flows into the slit 15 of the upper insulator hole 12, thereby ensuring further strength. The lower insulator hole 13 and the lower insulator projection 14 are heated and melted in the same manner.

[0022] The upper insulator protrusion 11 and the lower insulator protrusion 14, which protrude from the upper insulator hole 12 and lower insulator hole 13, were melted. This melted area takes on a lid-like shape, which helps to suppress axial displacement of the rotating electric machine.

[0023] As described above, according to this embodiment, by engaging the protrusion formed at the end of one insulator with the hole formed at the end of the insulator of another stator core, arranging and fixing the stator cores in an annular shape, and then heating and melting the protrusion protruding from the hole to assemble the stator, the connection of the stator cores becomes strong, preventing the stator core from splitting and shifting, and obtaining a stator with stable magnetic properties, thereby preventing a decrease in the efficiency of the rotating electric machine. As a result, the motor is not split during the manufacturing process, and the stator can be assembled uniformly, resulting in unprecedented and remarkable effects such as a reduction in motor efficiency due to variations in roundness.

[0024] Embodiment 2. The stator in Embodiment 2 will be described using Figure 11. In Embodiment 1, the stator core 5 was positioned by engaging the upper insulator projection 11 with the upper insulator hole 12, and the lower insulator hole 13 with the lower insulator projection 14. Subsequently, the stator 1 was assembled by melting the upper insulator projection 11 with the upper insulator hole 12, and the lower insulator hole 13 with the lower insulator projection 14. In Embodiment 2, as shown in Figure 11, the stator core 5 is guided by a jig 17 to form the annular shape of the stator 1, and the sides of adjacent upper insulators 6 are brought into contact as shown in Figure 12. Although not shown, the sides of adjacent lower insulators 7 are also brought into contact in the same way. Subsequently, the stator 1 is assembled by melting some or all of the engaging parts of the contacting upper insulators 6 and the contacting lower insulators 7.

[0025] Heating of the portion to be melted in the engaging part may be done from the axial direction, radial direction, or circumferential direction. Furthermore, it is not necessarily required to be from only one direction; heating from at least two directions—axial, radial, and circumferential—is also acceptable. Figure 13 shows the axially heated portion B and the radially heated portion C.

[0026] As described above, according to this embodiment, the connection of the stator cores becomes stronger, preventing the splitting and misalignment of the stator cores, and by obtaining a stator with stable magnetic properties, it is possible to prevent a decrease in the efficiency of the rotating electric machine. As a result, the motor does not split during the manufacturing process, and the stator can be assembled uniformly, resulting in unprecedented and remarkable effects such as a reduction in motor efficiency due to variations in roundness. Furthermore, by directly heating and melting the engaging parts of adjacent insulators that come into contact, it is not necessary to provide protrusions or holes in the insulators, and the connection of the stator can be made stronger with a simple structure.

[0027] Embodiment 3. The stator according to Embodiment 3 will be described with reference to Figure 14. In Embodiment 2, the sides of adjacent upper insulators 6 and lower insulators 7 were brought into contact and melted. In this embodiment, as shown in Figure 14, a welded portion 18 is formed at the end of one adjacent upper insulator 6, and a welded portion 19 is formed at the end of the other adjacent upper insulator 6. The welded portion 18 and the welded portion 19 are formed so that a portion of them overlaps radially. Similar welded portions and welded portions are also formed on the lower insulator 7. By engaging the welded portion 18 and the welded portion 19, they are assembled into a ring shape, thereby ensuring that the divided cores 4 are in contact without any gaps.

[0028] Subsequently, by melting the radially overlapping engagement portions of the welded portion 18 and the portion to be welded 19 while applying pressure from the radially outside, the stator core 5 can be positioned and fixed using the applied pressure from the radially outside.

[0029] Similar to Embodiment 2, heating of the molten portion may be from the axial direction, the radial direction, or the circumferential direction. Furthermore, it is not necessarily required to be from only one direction; heating from at least two directions—axial, radial, and circumferential—is also acceptable.

[0030] As described above, according to this embodiment, the connection of the stator core becomes stronger, preventing the stator core from splitting and shifting, and by obtaining a stator with stable magnetic properties, it is possible to prevent a decrease in the efficiency of the rotating electric machine. As a result, the motor does not split during the manufacturing process, and the stator can be assembled uniformly, resulting in unprecedented and remarkable effects such as a reduction in motor efficiency due to variations in roundness. Furthermore, by forming a welded portion and a welded portion that engage radially overlapping in the insulator, it becomes possible to consistently position and fix the stator core by melting the engaged portion under pressure.

[0031] Embodiment 4. The stator in Embodiment 4 will be explained with reference to Figure 15. Integrating the upper insulator 6 and the lower insulator 7 does not necessarily require melting the upper insulator 6 and the lower insulator 7; a separate component may be used for melting.

[0032] For example, as shown in Figure 15, the engagement portion where adjacent upper insulators 6 come into contact can be partially cut out in the circumferential direction, and a molten member 20 that can be fitted into the cut-out portion can be pressed against it and melted to integrate the engagement portion with the molten member 20. Similarly, the lower insulator 7 may also be melted using the molten member 20.

[0033] The molten member 20 to be fitted does not need to be made of the same material as the upper insulator 6 and the lower insulator 7; a less expensive resin material or a material that can provide greater strength may be used and melted.

[0034] Similar to embodiments 2 and 3, heating of the molten portion may be from the axial direction, the radial direction, or the circumferential direction. Furthermore, it is not necessarily required to be from only one direction; heating from at least two directions—axial, radial, and circumferential—is also acceptable.

[0035] As described above, according to this embodiment, the connection of the stator core becomes stronger, preventing the splitting and displacement of the stator core, and by obtaining a stator with stable magnetic properties, it is possible to prevent a decrease in the efficiency of the rotating electric machine. As a result, the motor does not split during the manufacturing process, and the stator can be assembled uniformly, resulting in unprecedented and remarkable effects such as a reduction in motor efficiency due to variations in roundness. Furthermore, by using a separate material for melting in the engagement part, a stator can be obtained at a lower cost or with higher strength.

[0036] Embodiment 5. The stator in Embodiment 5 will be described with reference to Figure 16. The members that integrate the stator core 5 do not necessarily have to be the upper insulator 6 and the lower insulator 7, but may be a separate member from the divided core 4, a divided core connecting member 21 that connects the divided cores 4 of adjacent stator cores 5. The divided core 4 is provided with a hole 22 for a divided core connecting member into which the divided core connecting member 21 can be inserted, and the divided core connecting member 21 is inserted. After that, the engaging portion of the divided core connecting member 21 and the hole 22 for the divided core connecting member, or the engaging portions of the divided cores 4 that are in contact with each other, are heated and melted.

[0037] This configuration allows the stator cores 5 to be combined by connecting the segmented cores 4, enabling the connection of all stator cores 5 that make up the stator 1 from the time the coils are wound onto the stator 1, thus eliminating the need for assembly in subsequent processes.

[0038] The split core connecting member 21 does not need to be the same material as the upper insulator 6 and the lower insulator 7; a less expensive resin material or a material that can provide greater strength may be melted into it.

[0039] Similar to embodiments 2 to 4, heating of the insertion portion between the divided core connecting member 21 and the hole portion 22 for the divided core connecting member, or the portion where the divided cores 4 are melted together, may be performed from the axial direction, the radial direction, or the circumferential direction. Furthermore, it is not necessarily required to be from only one direction; heating from at least two directions—axial direction, radial direction, and circumferential direction—is also acceptable.

[0040] As described above, according to this embodiment, the connection of the stator core becomes stronger, preventing the splitting and misalignment of the stator core, and by obtaining a stator with stable magnetic properties, it is possible to prevent a decrease in the efficiency of the rotating electric machine. As a result, the motor does not split during the manufacturing process, and the stator can be assembled uniformly, resulting in unprecedented and remarkable effects such as a reduction in motor efficiency due to variations in roundness. In addition, the engagement between the split core connecting member and the hole for the split core connecting member eliminates the need for subsequent assembly processes. Furthermore, by selecting the material of the split core connecting member, it is possible to obtain a stator that is cheaper or stronger.

[0041] Although this application describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but can be applied individually or in various combinations to the embodiments. Accordingly, countless variations not illustrated are conceivable within the scope of the technology disclosed herein. These include, for example, modifications, additions, or omissions of at least one component, as well as the extraction of at least one component and its combination with components of other embodiments. [Explanation of Symbols]

[0042] 1: Stator, 2: Rotor, 3: Rotating shaft, 4: Split core, 5: Stator core, 6: Upper insulator, 7: Lower insulator, 8: Back yoke section, 9: Teeth section, 10: Teeth tip section, 11: Upper insulator projection, 12: Upper insulator hole, 13: Lower insulator hole, 14: Lower insulator projection, 15: Slit, 16: Engaging section, 17: Jig, 18: Welding section, 19: Part to be welded, 20: Molten member, 21: Split core connecting member, 22: Hole for split core connecting member.

Claims

1. A method for manufacturing a stator, in which a plurality of stator cores, each having a divided core and an insulator that insulates the divided core from the windings, are arranged in a ring shape and assembled, characterized in that the stator cores are arranged in a ring shape, a protrusion formed at the end of one of the adjacent insulators is engaged with a hole formed at the end of the other insulator and provided with a slit, the protrusion is melted, and the molten protrusion is fixed in place by flowing into the slit.

2. A method for manufacturing a stator, in which a plurality of stator cores, each having a divided core and an insulator that insulates the space between the divided core and the windings, are arranged in a ring shape and assembled, characterized in that, after a welded portion formed at the end of one insulator of adjacent insulators of the ring-shaped stator cores engages with a portion to be welded formed at the end of the other insulator that radially overlaps a part of the welded portion, the engaged portion is melted while applying pressure from the radially outside, thereby fixing the stator core while positioning it by the applied pressure.

3. In a method for manufacturing a stator, in which a plurality of stator cores, each having a divided core and an insulator that insulates the space between the divided core and the windings, are arranged in a ring shape and assembled, A method for manufacturing a stator, characterized in that adjacent insulators of the annularly arranged stator core have a welded member made of a separate material from the insulator, and the welded member is melted and fixed.

4. A method for manufacturing a rotating electric machine, comprising adding a rotor mounting step to the stator manufacturing method according to any one of claims 1 to 3.

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